The octagonal, double-sided insert has 16 effective cutting edges, offering the lowest tooling cost per part in the industry
Kennametal’s Mill 16 has a wedge-style clamping system, numbered pockets and inserts, and an open pocket design to increase chip flow in heavy roughing
Iron is the most abundant element on earth by mass. For over twenty-five centuries it’s been used to plow fields, build bridges, cook food, and wage war. Without iron, the Industrial Revolution would have gone nowhere, we would have no trains, automobiles, or machine tools today, and mankind would still be an agrarian society. It is quite simply the most important metal in history.
There’s a newcomer to this metal family, though, one that’s making manufacturers take notice. As automakers strive for increasingly fuel efficient and environmentally friendly vehicles, they’re turning away from traditional iron favorites such as gray and ductile iron (GCI and DCI) to compacted graphite iron, or CGI. Also known as vermiculate graphite iron, CGI’s mechanical attributes meet or exceed its counterparts, sometimes drastically so.
Unfortunately, CGI is also more difficult to machine, requiring cutting tools both tough and wear-resistant. And because of the continuing call for cost-effective machining solutions across all manufacturing industries, these tools must also offer a low cost per part and predictable tool life. For face milling applications, that tool is Mill 16™ “Compared to cast iron, CGI has lower weight and greater strength, and is ideal for components that are exposed to both thermal and mechanical stresses like engine blocks and heads for cars and trucks, exhaust manifolds, and brake parts,” says Senior Global Product Manager for Indexable Milling, Marcelo Campos. “As with other cast irons, however, it is quite abrasive, and somewhat gummy to machine. We developed Mill 16 as a best in class face mill not only for CGI, but for all types of cast iron, which remains a popular choice for gear boxes, housings, pump bodies, and other components used in the automotive, agricultural, and heavy equipment sectors.”
Campos outlines Mill 16’s unique strengths as follows:
The finish machining operation on these ductile iron plates saw double the tool life and double the feed rate with Mill 16
Customer field tests have shown consistent and positive results. During a dry machining operation on a ductile cast iron plate using Mill 16, feed rates were increased by 41% and tool life doubled tool. A gray iron transmission case was machined at a feed rate of 0.39 mm per tooth (0.015 in.) and cutting speed of 208 m/min (682 ft/min), leading to reduced spindle loads compared to the legacy tool and slightly improved tool life. Metal removal rate and tool life on a water pump housing was more than doubled by switching to Mill 16.
There are more examples. Campos says he’s worked extensively with automakers and their suppliers, and in all cases the Mill 16 outperformed his competitor’s cutting tools. “We have cutting force dynamometers. We take videos. We run head to head tool life tests. For us to stand up and say we get 20% better tool life or 50% more metal removal than our next competitor, you can be certain it’s true. We at Kennametal are very excited about the Mill 16, and what it can do for our customers machining CGI and other types of cast iron.”
At the forefront of advanced materials innovation for more than 75 years, Kennametal Inc. is a global industrial technology leader delivering productivity to customers through materials science, tooling and wear-resistant solutions. Customers across aerospace, earthworks, energy, general engineering and transportation turn to Kennametal to help them manufacture with precision and efficiency. Every day nearly 12,000 employees are helping customers in more than 60 countries stay competitive. Kennametal generated more than $2.6 billion in revenues in fiscal 2015. Learn more at
Your email address will not be published. Required fields are marked *
Copyright © 2015. Divya Media Publications Pvt. Ltd. All rights reserved